Apparatus and method for remote monitoring and servicing material application systems

ABSTRACT

A system and related methods for configuring and monitoring a spraying application system for installation and use at a site that is remotely located from the spraying system manufacturing site. The system provides a configuration module that allows a customer or purchaser to configure a system electronically based on the customer&#39;s spraying needs. The selected configuration may further be linked to a pricing and inventory database module to allow the customer to order the system components, and obtain price and delivery schedules. In one embodiment, the configuration module is available to the customer via a secure web site over the Internet provided by a server accessed from a computer such as a personal computer at the customer&#39;s site. The system also provides a remote access module that provides spraying system operation and parametric information to be monitored at the manufacturing site to determine how the spraying system is operating and whether repair or maintenance should be initiated. Safety related parameters may also be monitored as a backup to the primary monitoring performed at the customer&#39;s site. The system also provides an extranet or other suitable site available, for example, via the Internet or other communication link, is used to provide an accessible database for historical data and configuration/installation information.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional patentapplication Ser. No. 60/222,890 filed on Aug. 3, 2000, the entiredisclosure of which is fully incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates generally to material spraying and applicationsystems including liquid and powder coating application systems. Moreparticularly, the invention relates to configuring, installing andmonitoring such systems from remote locations such as a field site orproduction/manufacturing site.

BACKGROUND OF THE INVENTION

Material application systems may be broadly categorized as liquid orpowder spraying systems. Liquid spraying systems may include, though notlimited to, paint, adhesives, conformal coatings, lacquers, powderslurries and so forth. Powder spraying systems may include powder paintcoatings and other non-paint materials in powder form such as lubricants(for example, powdered graphite) and food additives such as flavoringsand coatings for example; and powdered superabsorbants such as may beapplied to diapers.

Spray application systems can be rather complex systems in terms ofvarious control and safety functions. Such systems include an array ofone or more spray guns or spraying devices, pumps, material feed centersand overspray recovery systems. Some spray application systems includeelectrostatic spraying devices and most use pneumatic pressure as partof the application process. Many parameters may be monitored andadjusted including electrostatic voltage and current, air pressure,material pressure, flow rates, spray gun position, pump flow rates andso forth. Also, parts may be sprayed in a stationary condition within aspray booth or while moving through a spray booth via a conveyor system.Thus, an application system may include a number of sensors for positionand speed control of the conveyor system, as well as sensors associatedwith triggering control of the spraying devices.

Spray application systems are generally designed to maximize throughputwhile minimizing the amount of sprayed material, particularly tominimize the amount of overspray since overspray material does notadhere to the part being sprayed. Various spray patterns are availablebased on the type of spray nozzle selected as well as the type ofapplication system used. Accordingly, when a customer or end user isdeciding what type of system to install at a site, there may be a largenumber of available options in equipment, just as there are manydifferent types of parts to be sprayed and materials to be applied tosuch parts.

Heretofore, the process of configuring, installing andmonitoring/maintaining spraying application systems has beenaccomplished by time consuming and personnel intensive processes. Forexample, a customer or purchaser might first visit the manufacturer'ssite to observe the different spraying systems available and witnessvarious spraying demonstrations. A system is then recommended based onthe needs of the customer. The system may be built at the manufacturingplant first, test run in order to set optimal parameters, and thenshipped to the customer's plant. The system is then installed andoperated locally. If problems occur, typically a field servicerepresentative is then called out to the customer's site fortroubleshooting and repair. Historical records of system performance anddata histories, however, are typically site or customer specific, otherthan the possible feedback by the service representative to themanufacturing site. As to safety issues, fire detection systems arecommonly used with electrostatic application systems. Such detectionsystems have self-diagnostics but still must be monitored routinely forproper operation.

The general and greatly simplified process described above is very timeand labor intensive. Moreover, the process of detecting and/orpredicting the need for repair and maintenance efforts often results insystem downtime for the customer, which increases production time andcost.

The Internet and other information communication systems have greatlyfacilitated the ability of customers, for example, to studymanufacturer's product and system offerings from the remote customersite. Catalog databases and online purchasing/ordering systems allow acustomer to order parts directly from a desktop personal computer. Suchcatalog ordering systems have been commonly applied in many differentproduct fields from the sales of books to purchasing cars and so forth.However, such known systems do not adequately address the problemsassociated with complex manufacturing systems, particularly sprayapplication systems. Many times a customer may have minimal supportpersonnel at their site for monitoring system performance. Onlinepurchasing of parts from a catalog alone is inadequate for orderingcomplex spraying systems due to the wide variation in systemconfigurations as well as the need to configure a system with compatiblesubsystems and components. Known Internet and Web based systems also donot facilitate repair and maintenance activities.

It is an object of the present invention to provide apparatus andmethods for facilitating the configuring, installation and monitoring ofspraying application systems by the use of a data and informationexchange system that links a customer with the manufacturing site. Sucha system will preferably facilitate real time and historical monitoringfunctions and system configuration functions.

SUMMARY OF THE PRESENT INVENTION

The invention provides a system and related methods for configuring andmonitoring a spraying application system for installation and use at asite that is remotely located from the spraying system manufacturingsite. In accordance with this aspect of the invention, the inventionprovides a configuration module that allows a customer or purchaser toconfigure electronically a system based on the customer's sprayingneeds. The selected configuration may further be linked to a pricing andinventory database module to allow the customer to order the systemcomponents, and obtain price and delivery schedules. In one embodiment,the configuration module is available to the customer via a secure website over the Internet provided by a server accessed from a computersuch as a personal computer at the customer's site.

In accordance with another aspect of the invention, the inventionprovides a remote access module that provides spraying system operationinformation to be monitored at the manufacturing site to determine howthe spraying system is operating and whether repair or maintenanceshould be initiated. Safety related parameters may also be monitored asa backup to the primary monitoring activity performed at the customer'ssite. In one embodiment, the remote access module is implemented throughthe secure web site over the Internet. In accordance with a furtheraspect of the invention, an extranet or other suitable site available,for example, via the Internet or other communication link, is used toprovide an accessible database for historical data andconfiguration/installation information.

These and other aspects and advantages of the invention will be readilyunderstood and appreciated from the following detailed description ofone or more embodiments of the invention with reference to theaccompanying Figures.

DESCRIPTION OF THE FIGURES

FIG. 1 is a functional block diagram of an information exchange systemin accordance with the invention;

FIG. 2 is a functional block diagram and flowchart of a customerextranet site including maintenance, repair and information module suchas may be used in the system of FIG. 1;

FIG. 3 is a functional block diagram and software flowchart of aconfigurator module such as may be used in the system of FIG. 1;

FIGS. 3A and 3B illustrate exemplary configurator screens presented to auser;

FIG. 4 is a flowchart of a remote access module such as may be used inthe system of FIG. 1; and

FIGS. 5A, 5B and 5C illustrate in functional block diagram form variousapplication monitor functions that may be used with the presentinvention.

DETAILED DESCRIPTION OF PREFERRED AND ALTERNATE EMBODIMENTS

With reference to FIG. 1, the invention contemplates an informationexchange system 10 that facilitates the electronic configuration andpurchase operations, as well as supporting the installation andmonitoring of a spraying application system 12 located at a customerproduction site. Such production sites are typically geographicallyremote or distant from the manufacturing site of the sprayingapplication system. A customer may also have a number of production andsupport sites that are geographically remote from each other. A customersupport site may include purchasing, production engineering and soforth. Although the exemplary embodiments of the present invention aredescribed in the context of an Internet based information exchange ornetwork system, those skilled in the art will appreciate that theInternet is but one example of an open undedicated communication systemthat may be used to practice the present invention. Additionally,dedicated communication links via land wire and wireless modemconnections, optical communication systems, satellite communications andso forth are just a few examples of data and information exchangecommunication systems that may also be used with the present invention.The Internet is a preferred example because of the ability to accessinformation across the open network from virtually any location in theworld. By “open” is simply meant the ready access to the Internetnetwork via a server connected thereto, it being recognized that secureaccess is available through various data encryption and password controlscenarios.

Furthermore, although the described embodiments herein are in thecontext of exemplary spraying application systems, such examples areintended to be illustrative in nature and should not be construed in alimiting sense. The present invention may be used in a wide variety ofmaterial spraying application systems, including powder spraying systemsand liquid spraying systems, and further may be used in connection withthe spraying of a wide variety of articles such as but not limited tocar parts, electronic components, metal parts, non-metal parts, cans andother containers including biodegradable containers, and so forth. Theforegoing is not intended to be an exhaustive list by any means andshould not be construed in a limiting sense. Additionally, some or allof the aspects of the present invention may find application outside thematerial spraying technologies. Still further, although the describedembodiments incorporate various aspects of the invention into a singlesystem, such description is for convenience and ease of understandingand not intended to be limiting. The various aspects of the inventionmay be used individually or in any number of various combinations in aparticular system based on the particular needs of the customer. Forexample, a customer may avail itself of the configuration capability ofthe present invention but may decide not to incorporate a remote accessand monitoring function, or vice-versa. The terms “customer” and “user”are used interchangeably herein and in a broad sense to identify anyonehaving access to the various features of the system.

In FIG. 1 then, the system 10 includes a customer manufacturing orproduction site 12 that may include one or more spraying applicationsystems or system requirements. The production site 12 may include oneor more spraying application system monitoring modules 14 a, 14 b, 14 c.The monitoring modules 14 a,b,c are realized in a conventional mannerusing a number of sensors, gauges, detectors, controllers, actuators,valves, pumps and so forth that are typically linked to a local primarycontrol system (with possibly one or more local secondary controllers)such as a programmable logic controller (PLC) or other suitable controlsystem at the customer's production facility 12. Alternatively forexample a distributed embedded control system may be used. Themonitoring modules 14 a,b,c thus utilize a number of interactive systemcomponents that are provided by the manufacturer (“M”) or othersupplier, for example, to permit local monitoring and control functionsvia a controller. An example of such a local monitoring and controlsystem is described in U.S. Pat. Nos. 6,132,511 and 5,167,714 the entiredisclosure of which are fully incorporated herein by reference. Suchpatents may be referred to for details of a typical local control systembut should not be construed as limiting of the present invention. Manytypes of local control systems are well known to those skilled in theart and a detailed description thereof herein is not necessary to theunderstanding and practice of the present invention. By “local” issimply meant that the control and monitoring functions are implementedwithin the customer's site, but may include the feature of dedicated LANand WAN systems and other dedicated closed networked systems within theproduction site 12 and possibly linked to other dedicated closed networksystems of the customer.

One or more of the monitor modules 14 a,b,c may be connected to theInternet via a suitable interface controller and software module 16. Theinterface module 16, for example, may be realized based on a Windows™style or other suitable platform that provides data and otherinformation that is accessible via a web site 18 and web page linksaccessible through the Internet. The Internet access may be carried outin a conventional manner using a server that is connected to theInternet. In this embodiment of the invention, the top level web site 18is a public accessible web site and web page maintained on a server thatis under the control of the manufacturer M. The specific customerinformation and data however is accessed only through a secure customerspecific web page 20 link from the main page. Of course, a customermight not require a secure link but it is expected that in almost allcases a secure link will be used. A secure link may be realized, forexample, by a required user name and password combination. Higher leversecure access features such as public and private key exchanges and soforth may be used as required. The web pages and sites may beimplemented with conventional HTML language or other suitable software.The various databases described herein may be realized usingconventional spreadsheet programs or custom programs.

Access to the secure customer specific web site 20 thereby providesaccess to databases 22 that are requested by or provided to thecustomer. The particular content of the databases 22 will be customerspecific in many cases, however, in accordance with one aspect of theinvention it is contemplated that the secure customer web site 20 mayfunction as a customer extranet that is accessible by different customerproduction sites and support sites even if such sites are spreadthroughout the world. Alternatively, a customer may decide not to permitall of its sites to have full access to all databases within theextranet 20. Each customer site for example may have its own extranet 20with a secure access feature to all such extranets 20 being granted to acentral home office for example.

The databases 22 may include, for example, an interactivetroubleshooting module 24, a laboratory test records module 26 and ageneral database of records 28. The test records module 26 database willtypically be maintained by the manufacturer M based on system tests andinitial setup parameters prior to shipping the application system 12 tothe customer. The customer records database 28 may include a publicsection and a private section wherein the public section allows thecustomer to view historical data and other information unique to theirfacilities, whereas the private section permits a field technician orother representative of the manufacturer M to input repair andmaintenance information into the manufacturer's more detailed database.In either case, the customer only has access to its specific databases22.

In addition to the customer specific web site 20, the manufacturer M mayalso have access to its own Intranet site 30 via the public web site 18.Typically the Intranet site 30 will also be a secure access siteavailable only to the manufacturer M. This Intranet site 30 may containaccess to any number of databases and services pertinent to theoperation of the manufacturer's business selected by the manufacturer Mto be available on its Intranet, as is known in the art.

The invention also contemplates the capability for the customer toconfigure electronically a spraying application system 12 based on itsrequirements such as the type of articles being sprayed, the materialbeing sprayed and so forth. In accordance with this aspect of theinvention, via the customer web site or Extranet 20 the customer hasaccess to a configurator module 32. The configurator module 32 mayinclude a number of features as will be described hereinafter, includinganimation and other video functions 34. The configurator module 32 mayhave a configuration records database 36 for storing prior configurationrequests and any associated price quotes. The configurator module 32 mayalso interface to a pricing and inventory module 38 that provides priceand delivery information for various selected components of theconfigured system 12. A further link to an e-commerce marketing andsales site 40 may also be provided as required to permit conventionalcatalog sales and ordering processes.

The invention further contemplates a remote access function by whichpersonnel at the manufacturing site M have access to the operation ofthe application system 12 at the customer's site. In accordance withthis aspect of the invention, a remote access module 42 may be used toprovide a communication link over the Internet or other communicationnetwork to permit the manufacturer M to monitor the system 12performance. For example, the remote access module 42 may provide accessto the customer's production site via a secure web site 44 that ismaintained by the customer. Alternatively, the manufacturer may haveaccess to the customer's site via a dedicated communication network 46for added security. In either case, the monitored performance via themonitor modules 14 a, b, c are thus accessible to the manufacturer'spersonnel such as service technicians and design engineers. The remoteaccess module 42 may also include a link 41 to the database 22 to allowa field technician to update the database with the results of such anonline field service activity. Although the link 41 is illustrated asdirect to the database, in practice the link may be established througheither the manufacturer's Intranet 30 or the extranet 20.

With reference to FIG. 2 then, an exemplary flowchart for thecustomer/user Extranet web site 20 is illustrated. At step 100 thecustomer enters the manufacturer's M public web page by any suitableconnection to the Internet and selects the link to the specific productarea 102 of interest, such as powder spraying systems, liquid sprayingsystems, container spraying systems and so on. The customer may then bepresented at step 102 with a menu of choices including a link to thee-commerce catalog ordering and sales site 38, 40. The customer may alsobrowse general information made available by the manufacturer M or maylink to the customer's extranet site at step 104. The link into thecustomer's extranet will typically be through a secure web page such asby requiring a user name and password for example.

At step 106 the customer is presented another menu of options fromwithin its extranet site. An order link 108 may connect the customer tothe e-commerce site 38, 40 for pricing or status check of a customerspecific order (it being recognized that the e-commerce site may beseparately accessed by the customer from the main web site 18 if sodesired). A second option 110 will link the customer to the configuratormodule 32. Another option 112 will link the user to an equipment testresults database 114 which may be part of the laboratory test recordsmodule 26 (FIG. 1). The test results database 114 may include suchinformation as test date, product identification, test results and soforth including video or other visual data of tests and so forth.

Another option in the user's extranet site 106 is a link 116 to themanufacturer's public database 28. This database may be maintained bythe manufacturer M, the customer or both as required and will containhistorical data relating to repairs, initial setup parameters, spareparts lists, system profile information and any other useful informationthe user may want to know about the operation, performance, maintenanceand repair of the systems 12 in place. This database 28 is thus uniqueto the specific customer, and may be configured for access by all thecustomer's sites or only selected ones of the customer's sites. Separatedatabases may be provided for each customer site. An optional updatelink 118 may be used by the manufacturer to update the records database28 based on the latest field reports, repair reports and so on. Thecustomer and/or the manufacturer M may also update the database 28 viasteps 120, 122 when changes are made to the system 12 such as repairsand upgrades for example.

The customer extranet site 20 may also be provided with access by themanufacturer's service technicians at step 124 to permit the servicetechnicians to provide useful repair information. This information maybe entered into the manufacturer's private database at step 126 and thenthe data may be filtered if so required prior to updating the customer'sdatabase 28. The service technician may also link from the customer'sextranet page 106 into the manufacturer's Intranet site 30.

Another useful option presented to the user at the extranet site 106 isa troubleshooting module 128. When the system 12 is not sprayingproperly or other problems arise, the user may access thetroubleshooting module 128 to obtain helpful suggestions as to possiblesolutions. The module 128 includes a database that stores typicalproblems and suggested solutions. The troubleshooting module 128 mayalso be an interactive function such as a message board or chatoperation. The database may for example be developed from themanufacturer's historical data from the customer or all customers. Atstep 128 the user inputs system identification data and may type in aproblem description. An unsuccessful search at step 130 may promptadditional questions or may suggest a service representative call. Asuccessful search result 132 may be directly obtained from the initialquery at step 128 or additional queries at step 130. In either case, arecommended or possible solution may be presented along with optionalvisual demonstrations.

FIG. 2 is exemplary in nature as to the types of functions that may bepresented to the customer/user at its private extranet site. Thoseskilled in the art will appreciate that many other functions may beincorporated as required or some deleted as required. But the ability toprovide customer specific troubleshooting functions, database searchesand customer specific system configuration functions greatly enhance theeffectiveness of the spraying application system operation within thecustomer's production site 12.

The manufacturer's private Intranet 30 may also include a secureextranet feature to permit access by the manufacturer's personnel forsales reports and related information. This database may include suchinformation as news of recent installations, visual archives ofinstallations, sales report information, laboratory test results and soforth.

FIG. 3 provides an exemplary flowchart for a configurator module 32(FIG. 1) which permits a user to electronically configure a sprayingapplication system. At step 200 the user enters the public web site ofthe manufacturer M and at steps 202 and 204 enters the appropriatesecurity access information for gaining access to the customer specificweb site 20 (FIG. 1) as previously described hereinabove. At step 106(FIG. 2) the user can select the configurator module 32, andspecifically at step 206 selects the type of system to configure, suchas a powder spraying system. At step 208 the customer selects the typeof system components desired such as the pumping system and pumpselection, nozzle selection, filters, gun design, control systems and soon. At step 210 the customer enters specific information to hisparticular application such as the type of material, article dimensionsand type, conveyor feed rates, material type, weight, viscosity and soforth, as well as operating parameters such as temperature and desiredcoating characteristics such as film thickness. The data entered atsteps 208 and 210 will be dependent on the particular customer sprayingapplication needs. At step 212 the configurator software then canassimilate the data entered and perform a database query in order torecommend the various system components that the customer will need.Alternatively, if the customer is knowledgeable of the systemcomponents, the customer may directly select the components. Theconfigurator software 212 may then be used to detect whether thecustomer has attempted to make an invalid combination of systemcomponents. At step 214 the configurator software may query thee-commerce pricing and delivery database 38 for pricing and deliveryinformation, and may also present a visual representation of theselected system to the customer. Finally at step 216 the customer ispresented with a configuration number, quote number and any other usefultracking information, and this data may be stored for later access. Alink to the e-commerce ordering site 40 can then be used if so desiredto place the order.

It should be noted that the manufacturer M may also provide a publicconfigurator module that can be accessed from the manufacturer's publicweb site 18. This would permit a customer to “try out” variousconfigurations using a pick and choose approach rather than basing theconfiguration on specific customer parameters.

FIGS. 3A and 3B illustrate typical web pages that might be presented toa user as part of a configurator program. Many other options and methodsof presentation may be used. In FIG. 3A, the main screen 250 provides ageneral component list 252 and a visual representation 254 of the system12. The list 252 may provide a link for each component to a “drag anddrop” style of selection menu for example. A configuration “wizard”option 256 may be provided to facilitate component selection based on apreset series of questions about the customer's particular sprayingapplication. An example of a “wizard” option 256 is illustrated in FIG.3B. FIG. 3B may be realized using a single screen or a series ofscreens. The software selects the components based on the answers to thequestions 258 and at 260 provides a bill of materials. Various links 262as previously described can be used to connect the user to the pricing,availability and ordering modules.

With reference to FIG. 4, an exemplary embodiment of a remote accessmodule 42 is illustrated in flow diagram form as may be used, forexample, by personnel of the manufacturer M, such as technicians andengineers. In this case, the user from the user's local computer at oneof the manufacturer's M sites, selects remote access at step 300 whichtypically will be a customer specific software program that allows aninterface to the various monitor modules 14 a,b,c at the customer's site12. Alternatively, the modules 14 may be standardized thus permitting asingle program to access different customer sites (provided appropriatesecurity measures are maintained). At step 302 the user selects eitheran Internet based connection at step 304 or a direct or dedicatedconnection at step 306. Step 304 will require security accessverification at step 308, while a direct connection at step 306 willconnect via a data communication program which may be conventional. Ineither case the user connects into the manufacturer's control network atstep 310. This connection provides direct access to the customer'sInternet connection 16 (FIG. 1). At step 312 the user can monitor inreal time various operating parameters at the customer's site includingpressure, flow rates, fire detector status, review setup parameters andso on. At step 314 the customer is contacted to initiate a testsolution. At step 316 if the problem was corrected, at step 318corrective action is implemented by ordering parts as required with aservice call scheduled and so forth. At step 320 the actions taken maybe entered into the customer database 28 (FIGS. 1 and 2) and themanufacturer's private database 126 (FIG. 2). If at step 316 the problemwas not corrected, the algorithm returns to step 312 for another testsolution.

The remote access module 42 is particularly advantageous in supportingcustomers that may not have a large internal support function. The datacollected by the manufacturer M may also be used with expert systems toprovide predictive maintenance and repair functions. The remote accessmodule 42 can be used to not only monitor manufacturer suppliedcomponents such as spray guns and pumps, and so forth, but also inconnection with available software can monitor electronic devices suchas encoders and proximity switches. A field service engineer, forexample, may perform regular audits of a spraying application systemdirect from the engineer's desktop computer without having initially totravel to the customer's production site 12. Various parameters such asflame detection, dew point and proper grounding could be monitored andhistorically reviewed. Although most changes and adjustments would beimplemented via contact with the customer, remote modifications andchanges to various parameters such as pressure and flow rates may beimplemented with the appropriate software.

FIGS. 5A, 5B and 5C illustrate exemplary monitor modules 14 that may beused with the remote access concept of the present invention. Althoughthe examples in FIGS. 5A-5C are related to a powder spraying system,such description is intended to be exemplary in nature. The concepts ofthe present invention are equally applicable to liquid spraying systemsand spraying systems for containers, for example. In FIG. 5A a firedetection sensor 400 includes a self-test feature 402 and outputs aself-test status signal 404. The status signal 404 is input to the firedetection system controller 406 and further provides a status signal orsignals to the main system controller 410. In this example theapplication system 12 is a powder spraying application system. The maincontroller 410 interfaces through the Internet via a link 412 to themanufacturer's system via the remote access module 42 as previouslydescribed herein. In FIG. 5B, operational parameters may be remotelymonitored. The system controller receives various inputs from the partID controller 420, which detects the part ID and position using a numberof sensors 422. The main controller 410 interfaces with the spray guncontroller 424, for example, although the main controller may interfaceto other subsystem controllers such as a gun mover, spray booth, powderfeed center and so on. The subsystem controller 424 for example maycontrol operation of an electrostatic gun and related powder feed pump.The gun controller 424 receives various feedback signals 426 includingvoltage and current values and settings, air pressure readings, flowrates and so on. These signals may then be formatted and made accessibleto the remote access module 42 over the Internet or other suitablenetwork communication system. In addition to fire detection and gunparameters, the main controller 410 may provide additional monitoredparameters to the remote access module 42, such as for example, flowrates, ground monitors, fan speeds, pressure readings, dew points,triggering information, film thickness and so on. FIG. 5C illustrates ablock diagram of various monitoring functions that may be provided tothe manufacturer M via the remote access module 42. This is not intendedto be an exhaustive list but exemplary in nature and should not beconstrued in a limiting sense as to the available functions to bemonitored.

While the invention has been described with reference to a preferredembodiment, it should be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof.

Therefore, it is intended that invention not be limited to theparticular embodiment disclosed as the best mode contemplated forcarrying out this invention, but that the invention will include allembodiments falling within the scope of the appended claims.

1. A system for monitoring a material application system, comprising: aspraying application system in a first building site at a firstgeographic location; a spraying application system monitoring modulethat receives real time operating data from said spray applicationsystem and that is accessible to a communication network; saidmonitoring module formatting said real time operating data into signalsaccessible via said network; said real time operating data comprisingair pressure and material flow rates; and a remote access module in asecond and different building site than said first building site withsaid second building site being located at a second geographic locationthat provides access by a geographically remote user to acquire saidreal time operating data via said network.
 2. The system of claim 1wherein said network comprises the Internet.
 3. The system of claim 1comprising a database that contains historical operating parameterinformation, said database being accessible by said remote user via saidremote access module.
 4. The system of claim 1 wherein said database andoperating data are accessible via secure Web pages on the Internet. 5.The system of claim 1 wherein said remote access module accesses realtime operational parameters and corresponding parameters stored asinitial set-up values to permit geographically remote monitoring ofsystem performance.
 6. The system of claim 5 wherein said remote accessmodule accesses operating and historical data for trend analysis andpreventative maintenance.
 7. The system of claim 1 wherein said sprayingapplication system comprises a powder spraying system and wherein saidoperating data comprises powder flow rates, powder spray gun electricalpowder characteristics, powder spray gun triggering characteristics,powder film thickness characteristics and pressure characteristics. 8.The system of claim 1 wherein said operating data comprises a firedetection status signal.
 9. The system of claim 1 wherein said operatingdata comprises part identification and conveyer speed data signals. 10.The system of claim 1 wherein said remote user accesses said real timeoperating data and historical data to identify system malfunction. 11.The system of claim 1 wherein said remote user accesses said real timeoperating data and historical data to identify system malfunction.
 12. Asystem for monitoring and servicing a material application system,comprising: a material application system in a customer building site ata first geographic location; a material application system monitoringmodule that receives real time operating data including informationrepresenting a characteristic of the material from said materialapplication system and that is accessible to a communication network;said monitoring module formatting said real time operating data intosignals accessible via said network; said real time operating datacomprising air pressure and material flow rates; and a remote accessmodule in a second and different building site than said first buildingsite with said second building site being the manufacturer's site ofsaid material application system, said manufacturer's site being locatedat a second geographic location that provides access by a geographicallyremote user to acquire said real time operating data via said networkand analyze performance of said material application system.
 13. Thesystem of claim 12 comprising a database that contains historicaloperating parameter information, said database being accessible by saidremote user via said remote access module.
 14. The system of claim 12wherein said remote access module accesses real time operationalparameters and corresponding parameters stored as initial set-up valuesto permit geographically remote monitoring of system performance. 15.The system of claim 12 wherein said communication network comprises theInternet.
 16. The system of claim 12 wherein the remote user can accessand update a repair history database for said material applicationsystem.
 17. A method for monitoring and servicing a material applicationsystem, comprising the steps of: operating a material application systemin a customer building site at a first geographic location; accessingreal time operating data from said material application system over acommunication network; said real time operating data comprising airpressure and material flow rates; wherein said real time operating datais accessed from in a second and different building site than said firstbuilding site with said second building site being the manufacturer'ssite of said material application system, said manufacturer's site beinglocated at a second geographic location by a geographically remote userto acquire said real time operating data via said network and analyzeperformance of said material application system.
 18. The method of claim17 comprising the step of accessing historical operating data.
 19. Themethod of claim 17 comprising the step of accessing real timeoperational parameters and corresponding parameters stored as initialset-up values to permit geographically remote monitoring of systemperformance.
 20. The method of claim 17 comprising the step of accessingand updating a repair history database for said material applicationsystem.
 21. Apparatus for remote monitoring of a powder spray system,comprising: a powder spray system operating in a first building site ata first geographic location; a plurality of data devices for detecting aplurality of said powder spray system real time operating parametersincluding powder flow rate and air pressure and producing acorresponding plurality of real time data signals; a controller thatreceives said data signals and formats them for communication across acommunication network; a communication network; and a remote accesscomputer in a second and different building site than said firstbuilding site with said second building site being located at a secondgeographic location connectable to said communication network thatprovides access by a geographically remote user to acquire said realtime operating data via said network and analyze performance of saidpowder spray system.
 22. The apparatus of claim 21 wherein saidcommunication network comprises the Internet.
 23. The apparatus of claim21 wherein said operating parameters are selected to include at leastone of the following: fan speed, film thickness, flow rate, air quality,conveyor speed, electrical ground quality, electrical pulse rate andsequence, powder quality, part identification.
 24. The apparatus ofclaim 21 wherein said data devices comprise a fire detector.